4-65

4.9 Removal and installation of fuel tank as

4.9.2 Removal of fuel tank

Diagram Removal objects Tool

6. Remove filler tube 13:

a. Rotate loose turbine worm
clamp 18 and take off the Tool:
fuel hose. Open-end
b. Remove 3 bolts 12 from spanner 18#, 7#
filler tube flange, and
remove filler tube.

7. Remove fuel tank 1:

Remove the mounting bolts 6
and nuts 5 on the 4 fuel tanks.

 CAUTION

Fuel tank is connected to frame

through bolts and nuts in four
mounting points. After
mounting bolts are loosened, Tool:
fuel tank will separate from Open-end
frame. Before removal, use a spanner 30#,
reliable tool (e.g., forklift) with carrier tool or
sufficient bearing capacity to tooling
support fuel tank.

 CAUTION

Before step 7, make sure steps

2-6 have been done;
otherwise, corresponding parts
will be damaged, and even a
safety accident will occur.
4-66
4.9 Removal and installation of fuel tank as
4.9.3 Installation of fuel tank

4.9.3 Installation of fuel tank

Installation is in the reverse order of removal.
Notes: fuel tank mounting bolt has tightening torque of 600 ±50 N·m.

4.9.4 Cleaning of fuel tank

Remove suction flange cover in front of fuel tank, and wash internal surface of fuel tank. Unscrew drain
plug at bottom of fuel tank to drain fuel (use a proper container to collect fuel). Rinse it by fuel repeatedly
until the drained fuel is clean. Put drain plug back onto the floor of fuel tank.
4-67
4.10 Cooling system
4.10.1 Working principle of cooling system

4.10 Cooling system

4.10.1 Working principle of cooling system
Cooling system comprises a radiatorr and corresponding connecting lines, where the radiator is composed
of a water radiator, an air cooler, a hydraulic oil cooler and a torque converter oil cooler. Its function is to
radiate heat produced by each part (or system) into the air along with cooling air in order to ensure each
part works properly in appropriate temperature range.
As shown below, diesel engine cooling system mainly comprises a radiator (water tank), a water pump, a
fan, a thermostat, an engine oil cooler, water intake and outtake pipes, etc.

S/N Name S/N Name

1 Outfall sewer 6 Water pump
2 Circulating tubule 7 Engine oil cooler
3 Thermostat 8 Water drain valve
4 Radiator 9 Heating valve
5 Fan 10 Water temperature sensor

Cooling system of this machine adopts engine to drive fan and adopts suction mode to cool. The system
adopts forced closed circulating water cooling system. Working principle of system is as follows: water
outlet at lower part of cooler is connected with water inlet of engine oil cooler via water hose, water outlet of
engine oil cooler is connected with water pump via water hose, water pump pumps coolant into cylinder
block water passage, coolant firstly cools cylinder through water jacket inside cylinder block, then flows up
4-68
4.10 Cooling system
4.10.1 Working principle of cooling system

to cool cylinder head, and is collected by water outlet header pipe to reach thermostat. When coolant
temperature is lower than 84 ℃ , thermostat is closed, and all coolant is bypassed to water pump inlet. At
the moment, coolant is only circulating between cylinder block and cylinder head, so that warm-up can be
quickly realized. When coolant temperature is above 84 ℃ , thermostat starts to be opened, part of coolant
flows to water inlet at upper part of cooler and enters radiator to be cooled by cooling fan. When coolant
temperature is above 91 ℃ , thermostat is totally opened, bypass hole is closed, and all coolant is cooled
by radiator. The coolant flowing direction at the moment is shown in the chart.

1.Engine 2. Water radiator

Fig. The cooling system of diesel engine
4-69
4.10 Cooling system
4.10.1 Working principle of cooling system

Air cooler
Air cooler has the main function of cooling high-temperature high-pressure gas across turbocharger and
reducing temperature of air entering engine combustion chamber to increase air density. Its working
principle is shown in Fig. below. After air is pressurized by turbocharger, temperature rises up sharply,
pressure is increased, air flows into air cooler from left air pipe and passes across core of air cooler,
external cooling air flows by outside the core to bring away heat of air inside intercooler so as to reduce its
temperature to be lower than 80 ℃ , and then, the air flows into engine intake manifold and cylinder from
right air pipe of air cooler.

1.Booster air inlet 6.Intake manifold

2.Booster air outlet 7.Cylinder

3.Pressurized hot air 8.Exhaust gas

4.Air cooler radiator 9.Muffler

5.Pressurized cold air

4-70
4.10 Cooling system
4.10.1 Working principle of cooling system

The air cooler system of the vehicle arranged as the drawing below:

1.Air-air inter-cooler 2.Turbocharger

4-71
4.10 Cooling system
4.10.1 Working principle of cooling system

Hydraulic oil cooler

Hydraulic oil cooler has the main function of radiating heat generated by hydraulic oil during the working of
hydraulic system to avoid temperature of hydraulic oil line from being too high.
Torque converter oil cooler
Torque converter oil cooler has the main function of radiating heat generated by torque converter oil during
the working of transmission and torque converter to avoid temperature of torque converter and
transmission from being too high and ensure normal working of machine.

1. Hydraulic oil cooler 2. Torque converter oil cooler

4-72
4.10 Cooling system
4.10.2 Removal and installation of cooler lines

4.10.2 Removal and installation of cooler lines

Cooler lines
4-73
4.10 Cooling system
4.10.2 Removal and installation of cooler lines

Part No. Name Quantity Part No. Name Quantity

1 Water pipe 1 21 Turbine worm clamp 4
2 Hose clamp 3 22 Pipe clamp 2
3 Water pipe 1 23 Water pipe 1
4 Washer 3 24 Nut 1
5 Washer 18 25 Washer 2
6 Bolt 2 26 Bolt 1
7 Evaporator hose 1 27 Washer 2
8 Bolt 1 28 Intercooler steel tube 1
9 Nut 1 29 Intake hose 2
10 Washer 14 30 Heat shield 2
11 Nut 8 31 Bolt 1
12 U-clamp 2 32 Washer 1
13 Plate 1 33 Support 1
14 Bolt 6 34 Water drain valve 1
15 Turbine worm clamp 2 35 Water pipe 1
16 Clamp 8 36 Intercooler steel tube 1
17 Drain pipe 1 37 Water pipe 1
18 Steam hose 1 38 Plate 1
19 Refill hose 1 39 Support 1
20 Nylon strap 1 40 U-clamp 2

Tool list

Name Specifications
Open-end spanner 7#, 8#, 12#, 16#
Clean container, rubber tube
Plastic sealing bag
Nipper plier
Remark: removed standard parts should be placed with relevant material together to avoid confusion.
4-74
4.10 Cooling system
4.10.2 Removal and installation of cooler lines

Removal of cooler lines

Picture Steps Tool

1. Park the complete machine:

a. Park complete machine on
flat ground, apply parking
brake and shut down
engine. Remove the anti-
rotating bumper with a Tool:
nipper plier, connect the Nipper plier
bumper with the front and
rear frames with its pin.
b. Open engine hood, and
turn disconnect switch to
“OFF” position.
4-75
4.10 Cooling system
4.10.2 Removal and installation of cooler lines

Picture Steps Tool

2. Draining (oil/water)
a. Loosen water drain valve
34, select a proper
container to recover anti-
freeze (total capacity of
anti-freeze is about 45 L), or Tool:
select a proper hose to Clean container,
introduce water flowing out rubber tube
of water drain valve into a
container prepared in
advance, and tighten water
drain valve after emptying
coolant.

b. Loosen hydraulic oil cooler

drain valve or torque
Hydraulic oil drain valve converter oil cooler drain
valve, select a proper
container to recover oil (total
capacity of hydraulic oil
cooler is about 5 L/total Tool:
Drain valve of the torque capacity of torque converter Clean container,
converter
oil cooler is about 7 L), or rubber tube
select a proper hose to
introduce oil flowing out of
drain valve into a container
prepared in advance, and
tighten drain valve after
emptying oil.
4-76
4.10 Cooling system
4.10.2 Removal and installation of cooler lines

Picture Steps Tool

3. Remove the auxiliary tank -

Tool:
steam hose 18 of engine
Open-end
a. Remove the clamp 2 fixing
spanner 16#
the steam hose.

b. Loosen turbine worm

clamps at both ends of
Tool:
steam hose, and remove
Open-end
steam hose. Shield the port
spanner 7#
and steam hose with clean
plastic bags.
4-77
4.10 Cooling system
4.10.2 Removal and installation of cooler lines

Picture Steps Tool

4. Remove the auxiliary tank -

steam hose 7 of water
radiator
Remove clamp 2 from fixed Tool:
hose. Loosen turbine worm Open-end
clamp 21 at both ends of spanner 7#, 16#
steam hose, and remove
steam hose. Shield the port
and steam hose with clean
plastic bags.

5. Remove refill hose 19 of

auxiliary tank - water hose,
and remove clamp 22 fixing
refill hose. Loosen turbine Tool:
worm clamps 15 at both Open-end
ends of refill hose, and spanner 7#, 16#
remove refill hose. Shield
the port and water make-up
pipe with clean plastic bags.
4-78
4.10 Cooling system
4.10.2 Removal and installation of cooler lines

Picture Steps Tool

6. Remove the water radiator

pipe 1, 35 Tool:
a. Loosen captive nut 11 of U- Open-end
clamp, and remove U- spanner 16#
clamp 12.

b. Loosen shim clamp 16 of

water hose, remove water Tool:
hose, and shield ends and Open-end
water hose with clean plastic spanner 8#
bags.
4-79
4.10 Cooling system
4.10.2 Removal and installation of cooler lines

Picture Steps Tool

7. Remove the intercooler

steel tube 28, 36 Tool:
a. Loosen captive nut 11 of U- Open-end
clamp, and remove U- spanner 16#
clamp 40.

b. Loosen clamp 41 on intake

hose connecting both ends
Tool:
of pipe, remove pipe and
Open-end
intake hose, and shield
spanner 12#
ends, pipe and intake hose
with clean plastic bags.

Installation of cooler lines

Installation is in the reverse order of removal.
4-80
4.10 Cooling system
4.10.3 Removal and installation of radiator

4.10.3 Removal and installation of radiator

4.10.3.1 Removal and installation of radiator
Tool list

Name Specifications
Open-end spanner 7#, 8#, 10#, 12#, 13#, 16#, 20#, 24#
Torque spanner 160~680N·m
Inner hexagon spanner 8mm
Clean container, rubber tube, plastic sealing bag
Nipper pliers, scissors, nylon ties and cross screwdriver
Travelling crane and sling
Remarks: removed standard parts should be placed with relevant material together to avoid confusion.
Removal of radiator

Diagram Removal objects Tool

1. Park the complete machine

Refer to the first Step of
removal and installation of
cooler lines.
2. Draining (oil/water)
Refer to the second Step of
removal and installation of
cooler lines.
3. Remove auxiliary radiator to
steam hose of engine Tool:
Refer to the third Step of Open-end
removal and installation of spanner 16#, 7#
cooler lines.
4. Remove the refillhose
Tool:
Refer to the fifth step of
Open-end
removal and installation of
spanner 7#
cooler lines.
5. Remove the water hose
Tool:
mounting bracket
Open-end
Refer to Step 6a of removal
spanner 8#
and installation of cooler lines.
6. Remove the water pipe Tool:
Refer to Step 6b of removal Open-end
and installation of cooler lines. spanner 16#
4-81
4.10 Cooling system
4.10.3 Removal and installation of radiator

Diagram Removal objects Tool

7. Remove air intake hose

connecting air cooler
Tool:
Refer to Step 7b in removal
Open-end
and installation of cooling line
spanner 12#
(only intake hose at radiator
end is removed).
4-82
4.10 Cooling system
4.10.3 Removal and installation of radiator

Diagram Removal objects Tool

8. Remove fuse box

Cut off nylon strap fixing wiring Tool:
with scissors, loosen bolts Scissor, cross
fixing fuse box, remove fuse screwdriver
box, put it away properly.

9. Remove of hose of
hydraulic oil cooler
Tool:
Loosen screws on plate fixing
Inner hexagon
hose, remove plate and hose,
spanner, 8mm
and shield ends and hose with
clean plastic bags.
4-83
4.10 Cooling system
4.10.3 Removal and installation of radiator

Diagram Removal objects Tool

10. Remove the hose of

torque converter oil cooler
Tool:
Loosen screws on plate fixing
Inner hexagon
hose, remove plate and hose,
spanner, 8mm
and shield ends and hose with
clean plastic bags.
4-84
4.10 Cooling system
4.10.3 Removal and installation of radiator

Diagram Removal objects Tool

11. Remove A/C compressor

Remove compressor Tool:
according to removal and
Open-end
installation requirements and
spanner 10#, 16#
steps of compressor
hereinafter.
12. Remove upper cover
Remove engine hood Tool:
according to removal and Open-end
installation requirements and spanner #12,
steps of engine hood travelling crane
hereinafter.
13. Remove the protection
shield
Tool:
Remove protection shield
Open-end
according to removal and
spanner 13#
installation requirements and
steps of shield hereinafter.
4-85
4.10 Cooling system
4.10.3 Removal and installation of radiator

Diagram Removal objects Tool

14. Remove the radiator

a. Install lifting eyes on lifting
lugs on both sides of
radiator, and screw them in
at least by three turns.
Splice and tighten the lifting
tools to lifting eyes.
4-86
4.10 Cooling system
4.10.3 Removal and installation of radiator

Diagram Removal objects Tool

b. Unscrew the 4 mounting

bolts 17 on the radiator.
Tool:
Slowly lift radiator onto
Open-end
special tool with traveling
spanner 24#
crane and lifting sling, and
put away and collect shim.

Installation of radiator
Installation is in the reverse order of removal. Note: Make sure radial clearance between engine fan and
shroud is not less than 10 mm in assembly. Tightening torque of radiator mounting bolts is 305±25 N.m.
 4-87
4.10 Cooling system
4.10.3 Removal and installation of radiator

4.10.3.2 Removal and installation of radiator as

Installation of radiator
4-88
4.10 Cooling system
4.10.3 Removal and installation of radiator

Part No. Name Quantity Part No. Name Quantity

1 Radiator gp 1 17 Bolt 4
2 Shroud 1 18 Plate 1
3 Protection shield 2 19 Washer 8
4 Seal 2 20 Support 1
5 Washer 8 21 Support 1
6 Washer 8 22 Plate 1
7 Washer 8 23 Bolt 11
8 Nut 8 24 Nut 7
9 Bolt 8 25 Rubber plate 1
10 Plate 1 26 Auxiliary tank 1
11 Seal 2 27 Plate 1
12 Washer 37 28 Bolt 10
13 Washer 45 29 Seal 1
14 Bolt 24 30 Plate 1
15 Washer 4 31 Adjusting shim 4
16 Washer 4
Tool list
Name Specifications
Open-end spanner 13#, 16#
Remark: removed standard parts should be placed with relevant material together to avoid confusion.
 4-89
4.10 Cooling system
4.10.3 Removal and installation of radiator

Removal of the radiator mounting

Picture Steps Tool

1. Remove support 20, 21

Tool:
Loosen 8 captive bolts 14 of
Open-end
left and right radiator supports,
spanner 16#
and remove supports.

2. Remove auxiliary tank 26

Tool:
Loosen 4 mounting bolts 14 of
Open-end
auxiliary tank, and remove
spanner 16#
auxiliary tank.
4-90
4.10 Cooling system
4.10.3 Removal and installation of radiator

Picture Steps Tool

3. Remove protection shield 3

Tool:
Unscrew the 8 mounting bolts
Open-end
9 of the protective cover, and
spanner 13#
remove protection shield

4. Remove shroud 2
Tool:
Loosen 8 upper and lower
Open-end
captive bolts 14 of shroud, and
spanner 16#
remove shroud.
 4-91
4.10 Cooling system
4.10.3 Removal and installation of radiator

Picture Steps Tool

5. Remove the seal mounting

board 22, 10, 18 and 30
Successively loosen captive Tool:
bolts 14, 28 and 23 of upper, Open-end
left, right and lower 4 plates on spanner 16#
radiator, and remove seal
mounting plate.

Assembly of the radiator mounting

Installation is in the reverse order of removal.
4-92
4.10 Cooling system
4.10.3 Removal and installation of radiator

4.10.3.3 Removal and installation of radiator gp

Radiator gp

Part No. Parts name Quantity Part No. Parts name Quantity
1 Water radiator 1 11 Washer 4
2 Sponge 2 12 Bolt 4
3 Air cooler 1 13 Connecting bracket 1
4 Sponge 2 14 Bracket-lh 1
5 Hydraulic oil cooler 1 15 Water drain valve 2
 4-93
4.10 Cooling system
4.10.3 Removal and installation of radiator

6 Sponge 2 16 Shock absorber cushion 16

Torque converter oil
7 1 17 Washer 6
cooler
8 Sponge 2 18 Washer 6
9 Bracket-rh 1 19 Bolt 6
10 Washer 4 20 Connecting bracket 1
Tool list

Name Specifications
Open-end spanner 16#, 18#
Screw driver
Remark: removed standard parts should be placed with relevant material together to avoid confusion.

Removal of the radiator mounting

Picture Steps Tool

1. Disassemble the upper

plate 20
Tool:
Loosen and remove 6 captive
Open-end
bolts 19 of upper connecting
spanner 16#
plate, and remove upper
connecting plate.
4-94
4.10 Cooling system
4.10.3 Removal and installation of radiator

Picture Steps Tool

2. Unscrew the underneath

plate 13
Loosen 4 captive bolts 12 (do
not remove) of lower Tool:
connecting plate, so that left Open-end
and right supports 14, 9 can spanner 18#
rotate around lower
connecting plate by certain
angle.

3. Remove water radiator 1,

air cooler 3, hydraulic oil
cooler 5 and torque
converter oil cooler 7.
Split left and right supports by
certain angle with the aid of
straight screw driver,
successively take out water
radiator, air cooler, hydraulic
oil cooler and torque
converter oil cooler, and Tool:
collect sponge 2, 4, 6, 8 and screw driver
shock absorber 16.

 CAUTION

Hold radiator gp by someone

or use corresponding
stabilizing equipment to
prevent radiator components
from tilting when above 1, 2
and 3 operations are carried
out.